Consider using a timing belt drive. Not exactly a timing belt, but a cogged tooth belt.  They make cogged tooth belting specifically for linear actuators. You can buy it several inches wide so 6 hp would not be a problem.   I did a servo drive setup to propel a machine carriage with such a belt.  I think the belt was about 2 inches wide.  I think we used a 2 kw servo motor with a  gearbox.   It could produce about a thousand of pounds of pull.    You can buy the belting by the meter or foot.  I think it is "AT" belting that is generally used for linear drives.   Belts tend to be a bit elastic when pulled hard so you may need a 3+ inch wide belt.   But it can certainly move quickly.   The cost for the belting is quite reasonable.

On 4/11/2018 3:21 PM, John Kasunich wrote:

On Wed, Apr 11, 2018, at 3:08 PM, John Kasunich wrote:

On Wed, Apr 11, 2018, at 10:30 AM, David Berndt wrote:
I'm looking to output about 1000lbf in a linear direction via a
crank/slider or ballscrew
You don't mention the stroke length.  Are you moving a few inches in a
fraction of a second, or several meters over several seconds?
On further thought...

Ballscrew requires unreasonably high RPM.

Crank is very non-linear, and has major problems as stroke exceeds a couple 
inches - longer stroke means longer crank which means more and more torque is 
required.  You never use more than a half-revolution of the crank, so some 
serious reduction will be needed between motor and crank.

Have you considered roller chain?  Keep the sprocket size small so the torque 
doesn't get crazy high, but you can use multiple revolutions of the sprocket to 
cover an unlimited stroke.  Still going to require a gearbox; for a 1000 lbf 
load you will need a few thousand in-lbs  (few hundred ft-lbs) of torque, which 
is a LOT for any motor.

Interesting engineering problem to be sure.


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